Instruction manual

SHORT PARTS LIST 25/32
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL &
EXTERNAL SYSTEM 12/18-18/25-25/32
8 716 115 667a (05.2009)
52
FAULT FINDING
& DIAGRAMS
Start
Burner not operating normally.
Find symptom list below.
Intermittent
lockout
Are the combustion
settings correct for the
boiler & burner output?
Yes
No
Is the oil system a gravity
system?
Yes
Is the flue system
correct?
Yes
Are the electrical
connections on the
burner all sound?
Yes
Check the photocell using the
information under the control
box chart.
No NoNo
Rectify the combustion
settings.
Check for air in the oil:
rectify the oil line fault.
Change the flue system
to meet the literature
specifications.
Check all connections on
the burner and rectify
any faults.
Pulsation on
start up
Are the combustion
settings correct for the
boiler & burner output?
Yes
No
Is the flue system
correct?
Yes
Replace the nozzle and
recheck combustion.
No
Rectify the combustion
settings.
Change the flue system
to meet the literature
specifications.
High smoke
number
Is the fuel correct?
(kerosene only)
Yes
No
Is the flue system
correct?
Yes
Has the burner been
serviced?
Yes
Are the combustion
settings correct for the
boiler & burner output?
Yes
No NoNo
The oil system must be drained
& refilled with kerosene, then
recheck the combustion.
Rectify the flue system
to match one of the
available flue options.
Service the burner and
the boiler.
Rectify the combustion
settings.
No
Are all the combustion
head settings and
components correct?
Yes
Is the flue blocked or
restricted?
Yes
Replace the nozzle and
recheck combustion.
No
Change incorrect
parts/rectify settings.
Remove
blockage/restriction.
Check flue seals.
Noisy burner
operation
Is the noise due to
combustion?
No
Yes
Is the fan touching the
fan housing or causing
vibration?
No
Is the noise from the
motor?
No
Bleed the pump. Does
the noise reduce?
No
Yes YesYes
Check all combustion
settings.
Move the fan away from
the housing. Replace if
distorted or unbalanced.
Worn motor bearings:
replace the motor.
Air in the oil line:
investigate where the air
is getting into the oil line.
Worn oil pump: replace
the oil pump
Oil/
combustion
smells
Is there an oil leak? Check
all oil pipes & connections
for traces of oil
No
Yes
Is the flue blocked or
restricted?
No
Are the boiler combustion
chamber door, baffle & flue
access door seals leaking?
No
Are the burner seals
leaking? Check all seals.
No
Yes YesYes
Rectify oil leak, replace
components if necessary.
Remove
blockage/restriction.
Check flue seals.
Replace seals.
Replace any seals that
are damaged or suspect.
Check flue seals. Check
flue for damage.
BOILER LOCKOUT:
Indicated by the illumination of
the lockout indicator on the
burner.
To reset, wait 2 minutes then
press the lockout
indicator/reset button.
UNDER NO
CIRCUMSTANCES MUST
AN APPLIANCE BE LEFT
OPERATING WITH ANY
CONTROL LINKED OUT OR
OVER RIDDEN.
FAULT FINDING - BURNER
FUNCTION
These fault finding charts are provided to assist competent and suitably qualified engineers to locate and rectify faults. Whilst every effort has been taken to ensure the information given is correct and complete we cannot guarantee that every eventuality has been covered. Worcester, Bosch Group cannot be held responsible for costs incurred by persons not deemed to be competent.